问题处理的八大原则.ppt

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1、8D ANALYSIS STEPS8D 分析步驟分析步驟上完了上完了,也會分析也會分析1What is 8D?【失效分析及改善對策】8D 就是英文(8 Discipline)的縮寫，在生產的過程中，面對異常問題發生時，按照 8 個標題指示的步驟，提出治標及治本的改善方法。使用時機使用時機:(第一級)客訴問題分析 (第二級)廠內嚴重性異常 (第三級)生產線 TOP3 (第四級)生產線經常性問題Urgent/ImportantUrgent/unimportantNon urgent/ImportantNon urgent/unimportantI III IIIIIIIIIVIV2Overview

2、 of 8D DisciplinesD0-Prepare for 8D ProcessD1-Establish a Team 主題選定及團隊形成 D2-Describe the problem -粉重要粉重要 描述問題及現況掌握 D3-Develop Interim Containment Action(ICA)執行及驗證暫時防堵措施 D4-Define&Verify Root Cause and Escape Point 定義及驗證真因 D5-Choose&Verify Permanent Corrective Actions(PCAs)for Root Cause&Escape Point

3、 列出選定及驗證永久對策 D6-Implement&Validate Permanent Corrective Actions(PCAs)執行永久對策及效果確認 D7-Prevent Recurrence 預防再發生及標準化 D8-Recognize Team&Individual Contributions 恭賀團隊及未來方向 123Discipline 1 規則 1lIdentify the team champion 訂定小組競逐目標lSelect the team 選定組別4Discipline 2規則 2Problem Description問題描訴 Clearly describe

4、 the problem.明確描訴問題(Time,Place,Qty)lWhat object has a problem 什麼東西出現問題lWhere on the object is the problem 哪個部位出了問題lWhat is the problem 問題是什麼lHow big is the problem(use data:counts,%,trend charts,.)問題嚴重性(運用資料:讀值,百分比,趨勢圖,)5Discipline 3規則 3Interim Containment 過渡期圍堵 Explain how the problem is being cont

5、ained at the operation.說明問題如何在正常運作下正常運作下予以圍堵lUse data to verify containment prior to shipping 運用資料去驗證在出貨前的圍堵措施lCertification Data Before Containment:Example,14%defective 採行圍堵措施之前的佐證資料:例如,不良率14%lCertification Data After Containment:Example,0.2%defective 採行圍堵措施之後的佐證資料:例如,不良率0.2%lThe Data verifies the

6、quality of the containment action.由上述的資料來驗證圍堵措施的成效Famous 前 我漂亮嗎?針對現有生產線及出貨品需採取的短期處理對策針對現有生產線及出貨品需採取的短期處理對策6Discipline 4規則 4Identify and Verify Root Cause釐清與驗證根本原因lDetermine critical differences between problem areas and non-problem areas.找出介於有問題與沒問題的部位之間的關鍵差異點找出介於有問題與沒問題的部位之間的關鍵差異點(強調驗證強調驗證重覆性之確認重覆性

7、之確認)lDevelop a Process Flow Diagram.發展出一套圖解方式的製程流程圖lDevelop a Cause(Potential Root Cause)and Effect(Problem)diagram based on the main process functions in 2.依據上述的製程流程圖中的主要製程功能,延伸並找出問題的因(潛在根本原因)果(問題的影響)關係.lPrioritize the Potential Root Causes,most likely to least likely 將潛在的根本原因依其發生機率由最可能到最不可能予以排列.(使

8、用使用 製程製程 FMEA 模式進行模式進行)7Discipline 5規則 5Choose and verify permanent corrective action選擇與驗證長期的矯正措施lSelect the best corrective action.選擇最佳的矯正措施lUse a pre-production run to verify the effectiveness of the corrective action.運用量產前試作,來驗證矯正措施的有效性.lVerify the effectiveness of the corrective action.驗證此矯正措施最為

9、有效.8Discipline 6規則6Carry out the permanent corrective action(s)將長期矯正措施付諸行動 lDescribe the permanent corrective action.清楚描述此一長期矯正措施lUse a verification over time chart 運用時序圖來驗證有效性lto track the effectiveness of the action over time.依循時序逐一追蹤矯正措施之改善成果9Discipline 7規則 7Prevent reoccurrence of the problem預防問

10、題再發生lDescribe the changes to the manufacturing/quality system.清楚描述矯正措施對於生產與品質系統中的更動.lUpdate all design and purchasing checklists.更新所有設計與採購點檢表lUpdate the FMEA.更新失敗模式效應分析lNotify all personnel of the permanent corrective action.把此長期矯正措施傳達至所有員工lStandardize the new practice across all products/processes.

11、對所有生產或加工過程中的新對策都必須予以標準化10Discipline 8規則 8Congratulate the team 恭賀改善小組與結案11範例/動腦時間?葉金川?邱淑緹?Leader封鎖?監控?範圍?層級?立即Action112DateInitiated:11/27/02 PrepareBy:Brian SuUpdate:11/29/02Defect:20/35 SAMPLED20/35 SAMPLED IN MSP IQAMSP IQA FOUND STAINSTAIN IN COUNTER BORE OF RETURN Backgroundinformation:Upon fee

12、dback and verification at MSP incoming samples and pictures,Verification was done on the lots in MAT and incoming Returns.MINAIKFAILUREANALYSISRESPOND ON AURORABOTTOMASSEMBLYSTAIN LOCATION(magnified)2未記錄發生之時間13Findings:1.Verified MSP rejected sample and found similar to component Returns in MAT.2.Vi

13、sual naked eye inspection not easy to detect if not focus on area.With intended focus on the area,saw some small stain spots in the inner step of the counter-bore of Return.(see pic below)3.With 10 x scope,observed stain spots with gray stain around spots.4.Unable to be easily removed with IPA.Inves

14、tigation to understand defect:A)Screened incoming stock Returns and found similar spots stain.20/50pcs found.B)Put samples of spot stain for water boiling test,and found stain worsened.Magnified picsA)A)B)B)Before BoilingAfter BoilingNot easy to detectUnder naked eyeD414ImmediateActionduplicationexp

15、eriment:1.SUSPECTIMPROPERPRE-TREATMENTEFFECTDUETOQTYLOADINGLOADINGPERBARREL.nRunsamplestofullcapacityweightperbarrel(5kg)inplatingline.-observedpartswithstainspotsandfailedboilingwatertest.(magnifiedpics)nDecrease(samebatchofmaterial)weightofpartsperbarrel(2kg)inplatingline.-Observedpartswithoutstai

16、nandpassedwaterboilingtest.(with10 xMagnification.)beforeAfter Water boiling test 懷疑前處理出問題?加強前處理能力及減少 Loading15ImmediateActionduplicationexperiment:nRunsamplesevaluationtosetoptimumcontrolweightperbarrel.nRunsamples2kg,3kg,4kg,5kgqtyperbarrelObservation:1.Ifuse5kgperbarreltoload,therewillbeeasytofin

17、doutthestain.2.Ifuse2kgperbarreltoload,therearenotanystainintheparts.3 3.Usethe10XMagnifierandboilingtesttoverifytheresultWeightQtyBoiling Test Result15kg880 pcsNG24kg704 pcsNG33kg528 pcsOK42kg352pcsOKRemark:5.68g/per pcs2kg/Barrel5kg/BarrelMagnifiedMagnifiedpicspicsOKNG16na)Plating site(5pcs/load)n

18、b)MAT Incoming per 5pcs/lot.nC)10 x magnification Incoming inspection for stainRecovery Schedule:1.New parts with New improved Returns 600pcs ETD.Dec/3/2003.2.Another 1000pcs ETD.Dec/5/2003.3.Other schedule per PO:TBA4.Conclusion and Corrective Action.5.Experiment showed that the weight 5kg per barr

19、el has resulted poor removal of particles from the inner counter-bore surface of the Returns during pre-treatment,resulting the Nickel plating not covering the particle surface.6.Min Aik will immediately set 2kg per barrel load as a immediate control.Immediate Corrective Action17Containment Plan:At

20、MSP:1600pcs RTV for ReworkRework flow schedule to be advised(Dec/2/2002)FIG/WIP-TaiwanAt finished good store(Taiwan):Screened through 1000pcs found 456.Please see the Rework flow as belowComponent Returns MAT qty 2000pcsRTV and ScrappedComponent at Ten Rong qty 01819異常來源異常來源沖壓振研託工電鍍包裝IPQCOQCRMA設計出貨Other_機種機種發生日期發生日期/異常問題描述異常問題描述負責人：部門主管：問題接收部門問題接收部門 異常問題分析異常問題分析負責人：部門主管：研究或製程改善部門研究或製程改善部門矯正措施矯正措施負責人：部門主管：生效日：/問題發生部門問題發生部門(消除已發生問題點所採取之行動稱之為矯正)預防措施預防措施負責人：部門主管：生效日：/問題發生部門問題發生部門 (消除潛在性問題點所採取之行動稱之為預防)成效審查成效審查(QA)負責人：結案日：/品保部品保部製造工程生/物管業務研發品保20